Fluorothermoplastic Wire Extrusion coating

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Fluoro-thermo-plasticWire Extrusion coating

• Per Nelson
• Erik Peters
• Dyneon LLC

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Topics

• Polymers
• Conductor Payoff
• Sizing/cleaning
• Preheating
• Extruder
• Crosshead
• Tooling
• Cooling
• Gauges
• Troubleshooting

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Dyneon FEP, PFA, ETFE, THV
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Polymer uses
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Polymer line speeds
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Payoff

• Options
• Flier
• Roll-off
• Inline draw

• Flow stability is crucial
• back tension after flier
• tension brake

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Sizing/cleaning (solid conductors)

• Introduces tension to line
• Cleans copper surface
• Improved copper surface improved electrical
  transmission

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Copper Preheating

• Recommendations
• Temperature guidelines
• FEP/PFA100-180 C
• ETFE/THV 50 C
• Depends on linespeed
• Measurement
• Paper
• good comparative test
• universal

• Indicators
• High preheat
• Voided inner surface
• Smooth outer surface
• Better adhesion gtstrip
• Low preheat
• Rough outer surface
• Poorer adhesion

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Extruder

• Extruder specs
• L/D 24-341
• Saxton mixing 2-4 x diameter
• Close heat control necessary for a stable process
• corrosion protected material nickel alloy
• Extruder needs to have at least 400 C maximum
  temperature

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Crosshead

• Specs
• Fixed or adjustable center
• Corrosion protected material construction
• Coex/single extrusion possible

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Tubing

• Why tube extrusion?

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Melt fracture
Tubing
Smooth surface
Shark skin
Extruded film
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Tooling
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Tooling calculations
DDR (DD²-DT²)/(dCC²-dW²) DRB (DD/dCC)/(DT/dW)
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Cone

• Indicators
• Too long
• Diameter variation
• Unstable
• Too short
• surface roughness
• sparks/pinholes
• cone breaks
• Unstable
• Tip and die not concentric
• Core not centered
• Melt too hot or cold
• Line speed too high

• Recommendations
• 30-40 mm

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Cooling Trough
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Capstan

• Cold water spray typical
• Grooved sheaves preferable over stationary guides

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Gauges/Indications

• Line tension
• gauge of instability
• Identify conductor damage
• Inner (copper) diameter
• copper size and quality
• Capacitance
• crucial for foam
• adhesion problems
• eccentricity problems
• diameter problems

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Gauges/Indications

• Outer diameter
• Product size
• Long-term variation
• ovality
• Eccentricity
• Copper center
• Lump/neckdown
• Short term variation
• Spark tester
• holes, thin spots

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Troubleshooting
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Troubleshooting
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Troubleshooting
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Troubleshooting
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Troubleshooting
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Many Thanks

• Erik Peters
• Dyneon, Gendorf ?Kerkrade